A Guide to Using

Tensor DS and Tensor DL Drive with Tools Talk DS/DL

Atlas Copco Tools and Assembly Systems AB

Edition 3 Atlas Copco Tools and Assembly Systems AB - 9836 2050 01 Page 1 (145) 2003-09

Contents

1. SAFETY INSTRUCTIONS............................................................................................................ 5 2. INTRODUCTION ........................................................................................................................ 7

2.1 General .................................................................................................................................7 2.2 DS/DL Drive ........................................................................................................................7 2.3 System Functionality...........................................................................................................9 2.4 ToolsTalk DS/DL...............................................................................................................10

3. DS/DL DRIVE ........................................................................................................................ 11 3.1 Connectors DS ...................................................................................................................11 3.2 Connectors DL...................................................................................................................12 3.3 Inputs/Outputs Schematic ................................................................................................13 3.4 Installation of DS hardware .............................................................................................21 3.5 Installation of DL hardware.............................................................................................22 3.6 Installing new software into the DS/DL Drive................................................................23 3.7 DS Drive Dimensions ........................................................................................................24 3.8 DL Drive Dimensions ........................................................................................................25 3.9 Display / Key Pad DS Drive..............................................................................................26 3.10 Display / Key Pad DL Drive .............................................................................................27 3.11 Different models of DS/DL Drive.....................................................................................29 3.12 Functions, D302 / D303 and D312 / D313........................................................................31 3.13 Functions, D312 / D313 only.............................................................................................34 3.14 Key Pad Functions ............................................................................................................35 3.15 Remote Start ......................................................................................................................40 3.16 Inputs and Relays ..............................................................................................................41

4. PROGRAMS............................................................................................................................. 43 4.1 Selection of program .........................................................................................................43 4.2 Tightening strategies .........................................................................................................47 4.3 Special Functions...............................................................................................................53

5. TOOLSTALK DS/DL .............................................................................................................. 59 5.1 Installation .........................................................................................................................59 5.2 Working in Tools Talk......................................................................................................63 5.3 Programming Window .....................................................................................................72 5.4 Run Window......................................................................................................................80 5.5 Torque Tuning Window ...................................................................................................81

3

Contents

5.6 Configuration Window, Tensor DS & DL ......................................................................85 5.7 Configuration Window, Tensor DL only ........................................................................89 5.8 Diagnostics .........................................................................................................................95

6. PROGRAMMING...................................................................................................................... 99 6.1 Hints ...................................................................................................................................99 6.2 Full Programming of pset...............................................................................................103 6.3 Quick Programming .......................................................................................................108 6.4 Auto Set ............................................................................................................................109 6.5 Torque Tuning.................................................................................................................110 6.6 Configuration...................................................................................................................112

7. ACCESSORIES....................................................................................................................... 117 7.1 RE Alarm .........................................................................................................................118 7.2 Selector, only for D312 / D313........................................................................................120 7.3 I/O Expander ...................................................................................................................125 7.4 IR Key ..............................................................................................................................126

8. TROUBLE SHOOTING ........................................................................................................... 129 8.1 Error Messages in ToolsTalk DS/DL.............................................................................129 8.2 Error codes on Drive.......................................................................................................130 8.3 What might have happened........................................................................................137

9. TECHNICAL SPECIFICATIONS .............................................................................................. 141 9.1 DS Drive ...........................................................................................................................141 9.2 DL Drive...........................................................................................................................142 9.3 Tools Talk DS/DL............................................................................................................143

10. ABBREVIATIONS................................................................................................................... 145

4

Safety Instructions

1. Safety Instructions WARNING Read and understand all instructions. Failure to follow all the instructions listed below may result in electric shock, fire and/or serious personal injury. SAVE THESE INSTRUCTIONS IMPORTANT All locally legislated safety rules with regard to installation, operation and maintenance must be respected at all times. Refer installation and servicing to qualified personnel only. Work Area Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents. Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Power tools create sparks, which may ignite dust or fumes. Keep bystanders, children, and visitors away while operating a power tool. Distractions may cause you to lose control. Electrical Safety Earthed tools must be plugged into an outlet that has been properly installed and earthed in compliance with all relevant codes and ordinances. Never remove the earthing prong or modify the plug in any way. Do not use any adapter plugs. Check with a qualified electrician if you are in any doubt as to whether the outlet is properly earthed. Should the tools suffer electronic malfunction or breakdown, earthing provides a low resistance path to carry electricity away from the user. Applicable only to Class I (earthed) tools. THIS MUST BE EARTHED! Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is grounded. Don't expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. This instruction does not apply to tools classified as watertight or splash proof. For minimum electrical interference, place the instrument far away from possible sources of electrical noise, e.g. arc welding equipment etc. Do not abuse the cord. Never use the cord to carry the tools or pull the plug from an outlet. Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately. Damaged cords increase the risk of electric shock. Personal Safety Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tool while tired or under the influence of drugs, alcohol, or medication. A momentary lapse in concentration whilst operating power tools may result in serious personal injury. Dress properly. Do not wear loose clothing or jewellery. Tie long hair back. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewellery, or long hair can be caught in moving parts. Avoid accidental starting. Be sure switches are in the off position before plugging in. Carrying tools with your finger on the switch or plugging in tools that have the switch set to on invites accidents.

5

Safety Instructions

Remove adjusting keys or switches before turning the tool on. A wrench or a key that is left attached to a rotating part of the tool may result in personal injury. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the tool in unexpected situations. Tool Use and Care Use clamps or other practical means to secure and support the work piece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control. Do not force the tool. Use the correct Atlas Copco Tensor tool for your application. The correct tool will do the job better and safer at the rate for which it is designed. Do not use tool if switch does not work. Any tool that cannot be controlled by the switch is dangerous and must be repaired. Disconnect the plug from the power source before making any adjustments, changing accessories, or storing the tool. Such preventive safety measures reduce the risk of starting the tool accidentally. The mains plug is considered to be a disconnecting device. Disconnect the tool from the mains by pulling the plug from the socket in order to cut the power. Store tools out of reach of children and other untrained persons when not in use. Tools are dangerous in the hands of untrained users. Check for misalignment or binding of moving parts, damage, and any other condition that may affect tool operation. If damaged, have the tool serviced before using. Poorly maintained tools cause many accidents. Only use accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one tool may become hazardous when used on another tool. SERVICE Tools should only be serviced by qualified repair personnel. Service or maintenance performed by unqualified personnel could exposes users to serious personal injury. When servicing a tool, only use original replacement parts. Use of unauthorised parts or failure to follow Maintenance Instructions may create a result in electric shock or personal injury. CAUTION There is a danger of explosion if batteries are incorrectly replaced. Replace only with the same or equivalent type recommended by the equipment manufacturer. Discard used batteries in accordance with manufacturer's instructions.

6

Introduction

2. Introduction 2.1 General Tensor S electric nutrunners brought a minor revolution to controlled tightening. They are now the industry standard for critical joints with safety applications, though not economically feasible for use on joints throughout a whole plant.

Tensor DS is the alternative that lets you apply the benefits of advanced electric systems for controlled tightening on all the joints in your product. With Tensor DS you do not need to depend on mechanical devices or human repeatability to safeguard your joint integrity. Tensor DS means you can afford Tensor levels of operator acceptance, operator feedback, productivity, dependability, low service cost, multi-torque and joint control for all your tightening operations.

Tensor DL is the electric tool choice for small screw assembly. Its small size and good performance will increase productivity and reduce costs in your assembly operations. Tensor DL incorporates all the functionality of the Tensor DS, e.g. operator guidance, process control and rundown monitoring functionality.

2.2 DS/DL Drive The Tensor DS/DL electric nutrunners and screwdrivers are extremely fast and light. The Tensor DS/DL Drive does not use a torque transducer, instead it uses the unique Atlas Copco DigiTork system, proven to achieve excellent repeatability.

The Drive is programmed using the ToolsTalk DS/DL programming tool wich runs on a normal Windows based pc or lap top.

It is also possible to program the drive to a limited extend directly on the key pad, see section Key Pad Programming, chapter 3.10.

The Tensor DS Tools come in three different motor sizes DS4, DS7 and DS9, and can handle torques from 1 to 2000 Nm. Each tool requires its own drive unit.

Tensor DL can handle torques from approx 1 to 10 Nm. Each tool requires its own drive unit.

7

Introduction

Two different Drive versions There are two different functionality levels of the Tensor DS/DL system, the D302 / D303 Basic drive and the D312 / D313 Advanced drive with the possibility to program up to ten different parameter settings.

For DS Tools, each drive version comes for different tool sizes: DS4, DS7 and DS9.

For DL tools, there is only one drive version for all tool sizes: DL.

If you have multi-torque applications, you should definitely consider the benefits of D312 / D313. With ten different parameter sets on each tool you as much as halve your initial investment cost. You also benefit from lower installation costs and reduced backup inventory costs.

Besides the Multi Torque capability the D312 / D313 / 313 version is also equipped with: Digital Inputs, Relays, I/O-bus, Line Control, PLC functions, Rotate Spindle, Rundown Monitoring, Self Tap, High Speed Rundown and a Lock on Reject option.

ToolsTalk DS/DL fits with all drive versions (DS & DL) and will automatically detect the version of the drive, D302, D303, D312 and D313 and open up the appropriate functions.

8

Introduction

2.3 System Functionality The DS/DL System has no transducer in the tool. Instead of having an electrical signal from a strain gauge, the DS/DL Tool derives the torque from different relevant parameters in the motor, such as voltage, speed, temperature and current. A complete system consists of: The main power supply cable included with the drive Tensor DS/DL Tool Tool Cable DS/DL Drive Programming Cable ToolsTalk DS/DL PC / Lap Top

DS/DL Drive

DS/DL Tool

Application /Joint

External Torque Reference / IRTT

RE-Alarm

Socket TraySelector

PC /LapTop

The DS/DL System

115/230 volts

I/O

9

Introduction

2.4 ToolsTalk DS/DL

When programming the Drive a specially designed windows program is used for that purpose, ToolsTalk DS/DL. ToolsTalk is ordered as a single item and is needed in order to get full access to all functions in the drive. ToolsTalk DS/DL is an Atlas Copco made software running on a normal PC or Lap Top under Windows 95 (i.e. 32 bit Windows which includes Windows 95, 98, 2000 and NT but not Windows 3.X). It is used to program the Drive unit. Tensor DS is a system consisting of one Tensor DS/DL Tool, one cable and one Drive.

2.4.1 Important When Programming the Drive

When programming the Drive, It is of greatest importance to have a well developed second stage. The fastener/socket should allow some angle rotation in the second stage of the tightening, or else the torque may overshot. The best way to determine this is simply by observing the angle rotation during the second stage.

If the tool overshoots a red toggling led will show on the tool. The criteria for high torque is a short or a non-existing second stage in combination with a high speed in the first stage. On the display the message E003 will be shown.

Low torque is anything less than 98% of final target and occurs due to accidental release of the tool trigger during the tightening. It is indicated with a yellow toggling led on the tool. The torque value will be shown on the display.

10

DS/DL Drive

3. DS/DL Drive 3.1 Connectors DS

1

2

3

4

5

6

7

8

9

10

Displayed on the previous page is the back end of the DS Drive revealing all connectors. Each number corresponds to a specific connector that is explained below and in detail where needed. 1. Tool cable connector

2. Digital inputs. Only for D312 / D313. See Detailed Description on next page 2.

3. Relay outputs. See Detailed Description on page 3 3.

4. RS 232

5. I/O bus. Only activated for D312 / D313

6. I/O bus. Only activated for D312 / D313

7 Remote control

8. Main power connector

9. Ground fault interrupter, GFI, 30 mA

10. Main fuse. 6.3 X 32 mm - Slow Blow, 15/20/25 A

11. Main fuse: 5 X 20 mm Slow blow 6.3A

11

DS/DL Drive

3.2 Connectors DL 1

3004

470

8 9 10

4567 3 2

Displayed on the previous page is the back end of the DL Drive revealing all connectors. Each number corresponds to a specific connector that is explained below and in detail where needed. 1. Tool cable connector

2. Digital inputs. Only for D312 / D313. See Detailed Description on next page 2.

3. Relay outputs. See Detailed Description on page 3 3.

4. RS 232

5. I/O bus. Only activated for D312 / D313

6. I/O bus. Only activated for D312 / D313

7. Remote control

8. Main power connector

9. Power switch

10. Main fuse: 5 X 20 mm Slow blow 6.3A

12

DS/DL Drive

3.3 Inputs/Outputs Schematic Inputs

There are four opto isolated inputs on the drive. It is possible to have an additional six inputs through the CAN bus, but then you will need to have an I/O-Expander connected to the drive. The inputs can be configured to have the functions listed below.

For more information and programming of the I/Os, read chapter 5 and 6.

2a Fixed inputs Schematic on D302 / D303

Fixed input Description

Input 1 Reset Batch

Input 2 Batch increment

Input 3 Batch decrement

Input 4 Not used

2b Digital Inputs Schematic - D312 / D313

# Function Description

0 Not used The input is not activated

1 Reset lock on reject

If the checkbox Lock On Reject in the configuration window is marked and the tool is locked because of a faulty tightening, the tool will be unlocked when this input is activated.

2 Batch increment When this input is activated the batch counter will be increased one step, n=n+1.

3 Batch Decrement Decreases the batch counter one step, n=n-1.

13

DS/DL Drive

# Function Description

4 Reset batch Resets the batch counter to zero. No batch OK (nxOK). If batch OK is activated it will be deactivated.

5 Pset select bit 0

6 Pset select bit 1

7 Pset select bit 2

8 Pset select bit 3

P-set select input. The drive will interpret the inputs binary. Binary one will select p-set one, binary two will select p-set two etc. Binary 0=no p-set chosen.

Please read chapter 7.2, Selector.

9 Tool Tightening disable

Disables the tool to perform a tightening. Loosening will not be affected.

Note*

When CCW (counter clockwise) tightening direction is chosen the tightening direction will be the opposite from when CW (clockwise) tightening direction is chosen, and the tool disabled in CCW direction.

10 Tool Loosening disable

Disables the tool to loosen a fastener. Tightening will not be affected.

Note*

When CCW (counter clockwise) tightening direction is chosen the loosening direction will be the opposite from when CW (clockwise) tightening direction is chosen, and the tool disabled in CW direction.

11 Tool disable The tool will not start when this input is activated. If the tool is running it shall immediately stop when this input is activated. A new press on the start button is needed to restart the tool.

12 Ack error message

Acknowledge of an error. If the display flashes with an error code the error code will be acknowledged with a signal on this input.

13 Line control start Activates the tool if Line Control in configuration is chosen. See also Line Control.

14

DS/DL Drive

# Function Description

14 Line control alert 1 Activates relay Line Control Alert 1. See also Line Control.

15 Line control alert 2 Activates relay Line Control Alert 2. See also Line Control.

16 Set mono. relay 1 Activates Monostabile relay 1.

17 Set mono. relay 2 Activates Monostabile relay 2.

18 Set bistab. Relay 1 Activates Bistabile relay 1.

19 Reset bistab. Relay 1

Deactivates Bistabile relay 1 if Input Control under Relay Time is chosen on this relay.

20 Set bistab. Relay 2 Activates Bistabile relay 2.

21 Reset bistab. Relay 2

Deactivates Bistabile relay 2 if Input Control under Relay Time is chosen on this relay.

Note! - Relay Type Selector / RE-Alarm

As noted earlier, you may use Atlas Copco Tensor S series relay type selectors and RE-Alarms.

If choosing a relay type selector, you need to use adapter 4222 0417 00.

If choosing a RE-Alarm, you need to use adapter 4222 0472 00.

When combining both Re-Alarm and relay type selector, use adapter cable 4222 0486 00.

15

DS/DL Drive

Outputs Four output relays exists on the drive. It is also possible to have an additional eight relays by using the

I/O expander through the I/O bus. The relays can be configured to have the functions listed below.

3 a) Relay Outputs Schematic - D302 / D303

Fixed Output Description

Relay 1 OK

Relay 2 NOK

Relay 3 nxOK

Relay 4 Not used

3 b) Relay Outputs Schematic - D312 / D313 Programmable via ToolsTalk DS/DL

There are four events that can make the relay drop.

1. To next tightening When the start trigger is pressed and the tool is beginning the next tightening

2. Time When the timer has run out. The time is programmed in ToolsTalk DS/DL /Configuration

3. Tracking The relay is following a certain event. For instance tool running. As long as the tool is running the relay will be pulled

4. Input Control There are two relays that can be deactivated through inputs. These two are Reset bistabile relay 1 and Reset bistabile relay 2.

16

DS/DL Drive

# in TTDS / DL

Function Relay Time Description

To next tightening

Time Tracking Input Control

0 Not used The relay will not be affected

1 OK X X The relay will be pulled when all results are within limits.

2 nxOK X X The relay pulled when Batch OK, the batch counter is equal with the batch size programmed through Tools Talk DS / DL.

3 NOK X X The relay pulled when one or more results are outside limits or other not acceptable event has occurred, for example Rehit.

4 Low torque

X X Relay pulled when the torque value is too low. Possible reason due to start trigger released too early.

5 High torque

X X Relay pulled when torque value possibly high. The reason is because the second step angle is too small.

6 Tool tightening

X The relay is activated when the tool is running in the tightening direction. The relay drops when target is reached or the start trigger is released.

17

DS/DL Drive

# in TTDS/DL

Function Relay Time Description

To next tightening

Time Tracking Input Control

7 Tool loosening

X The relay is activated when the tool is running in the loosening direction. The relay drops when the start trigger is released.

8 Tool Running CW

X The relay is activated when the tool is rotating in clockwise (CW) direction.

9 Tool Running CCW

X The relay is activated when the tool is rotating in counter clockwise (CCW) direction.

10 Tool Running

X The relay is activated when the tool is running.

11 Switch in CW position

X The direction switch on the tool is turned in CW direction.

12 Switch in CCW position

X The direction switch on the tool is turned in CCW direction.

13 Tightening direction CCW

X The relay will be pulled when the selected p-set has CCW chosen as tightening direction.

14 DS/DL ready

X Relay pulled if the DS/DL Drive is ready to perform a tightening. No system errors occurs.

15 Tool ready X Relay pulled if the tool is ready to perform a tightening.

18

DS/DL Drive

# in TTDS / DL

Function Relay Time Description

To next tightening

Time Tracking Input Control

16 Tool locked

X Relay pulled when the tool is locked due to one or more of following:

Line Control without Line Control Start

Tool Disable

Tool Tightening Disable

Tool Loosening Disable

Lock On Reject

17 Service indicator

X Relay pulled until DS/DL Tool serviced.

18 Line control OK

X X Relay pulled when Line Control OK occurs.

19 Line control alert 1

X X Relay pulled when the Input Line Control Alert 1 is activated without having received Line Control OK. This is Line control warning 1, the first check point on the station.

20 Line control alert 2

X X Relay pulled when the Input Line Control Alert 1 is activated without having received Line Control OK. This is Line control warning 2, the second check point on the station.

21 Monostabile relay 1

X The relay is pulled if there is a signal on the input Set Monostabile Relay 1. The relay will follow the input and drop when the input goes low.

19

DS/DL Drive

# in TTDS / DL

Function Relay Time Description

To next tightening

Time Tracking Input Control

22 Monostabile relay 2

X The relay is pulled if there is a signal on the input Set Monostabile Relay 2. The relay will follow the input and drop when the input goes low.

23 Bistabile relay 1

X X X X The relay is pulled if there is a signal on the input Set Bistabile Relay 1. The relay will drop when there comes a signal on the input Reset bistabile 1 or when the next tightening is started or when the relay time is exceeded.

24 Bistabile relay 2

X X X X The relay is pulled if there is a signal on the input Set Bistabile Relay 2. The relay will drop when there comes a signal on the input Reset bistabile 2 or when the next tightening is started or when the relay time is exceeded.

20

DS/DL Drive

3.4 Installation of DS hardware Find a suitable place for the drive see Safety Instructions.

1. Mount the back panel preferable on a wall, A. For dimensions and screw holes, see chapter 3.7.

2. Hang the DS Drive on to the back panel, B. 3. Connect the cables, tool cable, power cable etc, to the connectors and fix the cables with

straps to the teeth on the back of the drive.

4. Check so that the GFI is switched on.

5. Fold the drive up and close it by turning the lock on the top of the drive, C.

6. Connect the power cable to a power supply, 115/230 V.

7. Connect a tool to the tool cable.

8. Turn the power on.

IMPORTANT!

Whenever replacing a tool, always turn the power off

DS Drive Back Panel Wall etc.

A B C

21

DS/DL Drive

3.5 Installation of DL hardware Find a suitable place for the drive see Safety Instructions.

Mount the back panel preferable on a wall, A (fig. 1). For dimensions and screw holes, see chapter 3.8.

Hang the Drive on to the back panel (fig. 2), attach the fixing screw (fig. 3) in the lower right corner of the drive.

Connect the cables, tool cable, power cable etc, to the connectors and fix the cables with straps to the teeth on the inside of the protection plate.

Close the protection plate by attaching the plate screw to the drive.

Connect the power cable to a power supply, 115/230 V.

Connect a tool to the tool cable.

Turn the power on.

IMPORTANT! Whenever replacing a tool, always turn the power off

DL Drive Back Panel Wall

22

321

s002

590

A B C

DS/DL Drive

3.6 Installing new software into the DS/DL Drive Installation guide for software versions 4.4 and higher 1. Connect a tool.

2. Turn the power on.

3. Turn your PC/Lap Top on.

4. Start Windows Explorer.

5. Create a new directory and put the drive sw on the hard drive/c:.

6. Go to the directory where the software is stored.

7. Double click on the dlds_com1.bat or dlds_com2.bat depending on what com port is used on your PC/Lap Top*.

8. A dos-window will be opened and the drive software loaded automatically, it will take approximately 2 minutes. The drive will power off while loading the soft ware.

9. When the software is loaded the drive will power up automatically and the display will show four dots or four dashes.

10. If the drive does not power up, please retry the procedure, read chapter 7 Trouble Shooting or contact your local Atlas Copco dealer.

*If you are using com port 3 or higher please do following:

1. Open a dos window

2. Go to the directory where the sw is located

3. Write dlds COM3 or dlds COM4 etc. and press enter. (This command will also work for COM1 and COM2). Note! Use capital letters.

If you have software version 4.4 or higher start with number 7 and the init - command.

23

DS/DL Drive

3.7 DS Drive Dimensions

7 for M

6 screw

9042

25

324

401

30050

356

93

399

673

2Cable

out

let17

4

4

DS/DL Drive

3.8 DL Drive Dimensions

3004

450

(mm)

25

DS/DL Drive

3.9 Display / Key Pad DS Drive

TENSOR DS7

20.681 2 3 5 6 9 10

4 7 8 11 12 13 14 15

1. Display 9. Function 2. OK LED 10. Autoset 3. n x OK LED 11. Plus button 4. Lock LED 12. Question mark 5. NOK 13. Enter key 6. Alarm 14. Minus button 7. Graph 15. Power 8. IRDA

The DS Drive is primarily designed to be programmed using ToolsTalk DS. However, there are a number of programming features available directly through the key pad on the Drive. See chapter 3.14 Key Pad Programming

26

DS/DL Drive

3.10 Display / Key Pad DL Drive

1

14

8

9 1310

5 2 3 4 7 11

6

12 3004

480

1. Display 8. IRDA 2. OK LED 9. Function 3. n x OK LED 10. Autoset 4. Lock LED 11. Plus button 5. NOK 12. Question mark 6. Alarm 13. Enter key 7. Graph 14. Minus button

The DL Drive is primarily designed to be programmed using ToolsTalk DL. However, there are a number of programming features available directly through the key pad on the Drive. See chapter 3.14 Key Pad Programming

27

DS/DL Drive

1. Display Displays numerical values up to 9999. 2. OK LED Lights up after each tightening producing correct torque 3. n x OK LED Lights up after a batch of OK tightenings (n) set through

ToolsTalk DS/DL. Not D302 / D303. 4. Lock LED Lights up when the DS/DL Drive key pad has been lock

unlocked by either the IR-Key or through ToolsTalk DS/DL. 5. NOK Lights up after each tightening reaching first target but not

correct torque. 6. ALARM Lights up to indicate triggered internal alarms, for example, time

to service the tool or errors that need to be acknowledged. 7. GRAPH Lights up when the SET button is pushed to indicate that. Auto-

Set, is activated through the drive key pad. 8. IRDA Underneath this window the IRDA transmitter and receiver is

located. When using the IR-key, point it towards this window. 9. Function The function key shall be used for selecting DS/DL Drive functions

Function key shall be operable when keyboard is in unlocked state. When operator wants a function he activates the Function key.

10. Auto set Pushing this button allows Auto-Set programming to be conducted; perform torque tuning, adjust final target and perform motor tuning DS/DL Drive must first be unlocked.

11. +Torque Each push raises the final target by one increment, 0.1 or 1. By pressing the button continuously final target final target will be raised by one increment at an increasing speed

12. Question mark By pushing this button you can see: Drive program software version Drive size (DL, DS4, DS7, DS9) Drive version (D302 / D303, D312 / D313)

13. Enter Enter key shall be used for execution of selected functions and acknowledge of errors.

14. -Torque Each push lowers the final target by one increment, 0.1 or 1. By holding the button pushed in the final target will be lowered by one increment at an increasing speed.

15. POWER Main power switch.

28

DS/DL Drive

3.11 Different models of DS/DL Drive Both of the two tightening systems (DS & DL) are available in two different models which can be programmed with one, D302 / D303, or eight, D312 / D313, different parameter sets, p-sets. A (p-set) is the specific programming for a certain joint. In other words one Tensor DS/DL System can do up to ten different torque levels. The p-sets are selected using the digital inputs a Turn Selector or a Socket Tray. Of course, p-sets can also be changed through ToolsTalk DS/DL.

D302 / D303 Single P-Set Drive The D302 / D303 Drive is a single torque drive, handling one p-set. It has the following main functions: OK Relay NOK Relay nxOK Relay Reset Batch Input Increment Batch Input Decrement Batch Input Auto Set Quick Programming Torque Tuning Tool Signal Lights Tool Service Indicator CCW, Counter Clockwise Tightening Direction Open End Spanner Batch Count Remote Start Lock on reject Rundown Monitoring Self Tap functionality High Speed Rundown

29

DS/DL Drive

D312 / D313 Multi P-Set Drive The D312 / D313 is a multi torque drive capable of handling up to ten different p-sets. Except for the functions in D302 / D303 it is also equipped with:

RE-Alarm

PLC Functions

Line Control

Socket Tray/Selector

I/O Expander

Up to 12 I/Os

Rotate Spindle

I/O Bus

10 Parameter Sets

30

DS/DL Drive

3.12 Functions, D302 / D303 and D312 / D313 OK Relay Pulls Relay 1 (D302 / D303) when an OK tightening is performed.

NOK Relay Pulls Relay 2 (D302 / D303) when a tightening reaching at least first target but NOT correct torque.

NxOK Relay Pulls relay 3 (D302 / D303) when a batch of OK tightenings has been completed.

Reset Batch Input Resets the batch counter (Input 1 on D302 / D303) when activated.

Increment Batch Input Increases the batch counter (Input 2 on D302 / D303) one step when activated.

Decrement Batch Input Decreases the batch counter (Input 3 on D302 / D303) one step.

Auto Set Auto Set only requires the Final Target, the rest of the parameters are calculated and programmed automatically by the Drive while you perform a number of test tightenings. The Auto Set function does not require the PC to be connected, it can be done by using the keypad on the Drive. For more information, see chapter 3.10, 4.1 and 6.4 Auto Set.

Quick programming Quick programming is a function to be used through ToolsTalk. Two parameters are given by the operator, stiffness of the joint and final target, and the rest will be programmed automatically.

31

DS/DL Drive

Torque Tuning Torque Tuning is performed either from the key pad on the drive or through ToolsTalk. It allows an easy adjust to your reference system torque values and compensates for tool-drive-programming and joint variations. One torque tuning factor is stored with each p-set. For more information, see chapter 5 and 6.

Tool Signal Lights Gives light signals on the tool and drive to indicate OK or NOK tightenings and other faults.

Green light indicates OK tightening.

Yellow light indicates low torque.

Red light indicates high torque.

Red and yellow light combined indicate all other faults.

Tool Service Indicator Alarm lights up and a programmed relay is pulled when the programmed service interval is reached.

Counter Clockwise Tightening Direction, CCW All DS/DL Drives have a built in functionality for left hand threaded fasteners.

Open End Spanner All DS Drives have a built in functionality for open end spanner applications.

Batch Counter By counting number of OK rundowns and give an nxOK signal when a certain number n is reached you can assure that a job has been completed properly. The number of rundowns n in the batch counter is set in ToolsTalk. It is also possible obtain the nxOK signal on a relay. External input signals for batch increment and reset batch are configured through ToolsTalk DS/DL.

32

DS/DL Drive

RE Alarm A RE-Alarm is possible to connect to the Drive. The RE Alarm is a portable device, connected to the drive with a cable, that can be placed near the operator to give signals for OK, NOK and nxOK.

There are two types of RE-Alarms. One connects to the Relays and one to the I/O-bus, see table below. Note that Type of RE Alarm.

Drive version the drive software needed for the I/O-bus to work must be v4.4 or higher.

Type of RE Alarm Drive version Relay RE Alarm

I/O Bus RE Alarm 8433 0560 03

D301 X

D311 X X SW v4.4 or higher

D302 / D303 X

D312 / D313 X X SW v4.4 or higher

In order to use RE-Alarm 8431 0455 36 you need a special adapter cable, no 4222 0472 00. When using both Re-Alarm and Tensor S/PF 2000 relay type socket tray/selector in combination, then use adapter cable 4222 0486 00.

IR Key The IR Key is used to get access to the key pad on the drive. By pressing the button on the key while pointing it towards the IR window on the drive, it will be unlocked.

33

DS/DL Drive

3.13 Functions, D312 / D313 only I/O Bus RE Alarm There are two types of RE Alarms, one I/O bus based and one that uses the relays. For RE Alarm with digital input, please see chapter 3.8.

When using the relay based RE Alarm 8431 0455 36, please read chapter 3.8.

When using the I/O Bus based RE Alarm 8433 0560 03, please read chapter 7.1.

Line Control The D312 / D313 Drive supports a special Line Control function. See chapter 5 and 6.

Socket Tray/Selector The I/O bus based selector tray comes in two different versions, selector 4, 8433 0610 04 which has four positions and selector 8, 8433 0610 08, with eight positions. For more information, see chapter 7.2.

Lock on Reject To assure that no faulty tightenings are passed on unnoticed, this function will lock the Tool/Drive on rejected tightenings. The tool will not be able to run when locked and the operator must then Reset Lock On Reject before next tightening.

34

DS/DL Drive

3.14 Key Pad Functions The DS/DL Drive can be programmed directly to a limited extent through the key pad on the front panel. There are five functions available and also a possibility to change parameter sets: F1 = Auto set F2 = Final Target F3 = Torque Tuning F4 = Motor Tuning. F5 = Copy Parameter set

+/- button = Change Parameter set (when the +/- button not is used for another function)

Auto-Set Programming This enables authorized personnel to program a Drive unit right out from a box without ToolsTalk DS/DL. The Auto-Set Programming feature allows the Drive to recognize a joints stiffness and adjust the tool for maximum performance for that particular joint accordingly.

How to program AutoSet 1. Press the AUTOSET button (= Dart Board button symbol) once. 2. Choose final target by pressing the +Torque or -Torque buttons on the drive key pad. 3. Press the ENTER button once to activate the Auto Set function. The Graph,

LED, lights up. 4. Resume tightening. The first tightening is performed at a very low speed as the

DS/DL Drive identifies the joint. The speed will gradually increase during the following tightening as the DS/DL Drive is optimizing the performance for that joint. When the Graph LED lights down, optimum performance has been found.

Note! Every tightening will reach final target and the programmer can at any point during this process press the SET button, when he or she is satisfied with the tightening results, and thereby set the tightening characteristics at that point as maximum performance. Again, this lights down the Graph LED and the DS/DL Drive is programmed.

Lock the DS/DL Drive. It will also automatically resume a locked position approximately 15 minutes after the last entry on the key pad.

35

DS/DL Drive

Fine-Tuning Final Target This enables authorized personnel to fine tune the final target, on site, without assistance from ToolsTalk DS/DL.

1. Unlock the DS/DL Drive with either an IR-Lock or through ToolsTalk DS/DL.

2. Enter the mode to change final target by pressing the FUNCTION button once and Ft/F2 appears on the display.

3. Adjust the final target by pressing the +Torque or -Torque buttons on the DS/DL Drive key pad.

Note! Using this programming option, torque can be adjusted a maximum of +15% or -5% from the original final target set through ToolsTalk DS/DL or Auto-Set. All values are stored automatically in the DS/DL Drive memory as they are entered.

4. Press the ENTER button and the display starts to twinkle.

5. When a new final target has been found within above limits, the DS/DL Drive is ready to run that program. Lock the DS/DL Drive. It will also automatically resume a locked position approximately 15 minutes after last entry on the key pad.

36

DS/DL Drive

Torque Tuning This is used when a tool is controlled against an external torque reference for calibration. There is one torque tuning factor each parameter set.

1. Unlock the drive.

2. Perform a number of tightenings with the external torque gauge connected, preferably 20 tightenings or more so a good mean value can be achieved.

3. Calculate the mean value from the tightenings.

4. Press the FUNCTION button twice and you see tunE/F3 on the display.

5. Press the + or - button until you have the external mean value on the display.

6. Press the ENTER button, the display starts to twinkle.

7. Perform another set of tightenings to control your torque.

8. If the torque is OK you are ready to run, if not, do the complete procedure over again.

9. Lock the drive.

Motor Tuning

This function will optimize the performance of the motor and minimize losses.

1. Unlock the drive. 2. Press the FUNCTION button three times until tool/F4 shows on the

display. 3. Press the ENTER-button once again until the display starts to twinkle. 4. Press the trigger on the tool and run until it stops. The procedure will take

approximately 35-45 seconds. The tool has now been motor tuned and is ready to use.

37

DS/DL Drive

Copy Parameter set This option makes it possible to copy a parameter set. 1. Unlock the drive 2. Press the FUNCTION button four times until it says Copy/F5

on the display. 3. Press the + or button to select the parameter set you want to

copy to another parameter set. Confirm by pressing the ENTER buton.

4. Choose the parameter set that you want to copy the selected parameter set to by pressing the + or buttons again. Confirm by pressing the ENTER button

5. Lock the drive

Change parameter Set When neither of the described functions are selected, the + and buttons are used to change parameter set. 1. Press + or button to select wanted parameter set 2. Confirm that you want to change Parameter set by pressing the

ENTER button. Note! If you dont confirm with the enter button the tools will continue with the former parameter set

Drive software, Drive hardware and Tool version The question mark will give information on what software version and drive version your drive has. Process as follows:

1. By pressing the QUESTION MARK button once you will get information of the software version.

2. By pressing the QUESTION MARK button twice the drive hardware version will bee shown, D302 / D303 or D312 / D313.

3. By pressing the QUESTION MARK button three times the display will show the tool version.

38

DS/DL Drive

Display Tool

DS4 ETV/ETD/ETP DS4

DS7 ETV/ETD/ETP DS7

DS9 ETV/ETD/ETP DS9

DL21 ETV/ETD/ETP/DL21

DF4 ETF DS4

DF7 ETF DS7

DF9 ETF DS9

Note! ETF = fixtured Tensor DS/DL Tool

39

DS/DL Drive

3.15 Remote Start Note 1! When starting more than one Drive from the same start signal, use start box 4222 0550 00

Note 2: When setting up a Tensor DL Drive for remote start, ensure that the start option Remote start, tool button deactivated is selected in the Tool Configuration menu in the Configuration section of Tools Talk DS/DL. Then also rewire the the Remote Start connector according to Remote Control Wiring Schematic.

4

3

2

1

Tool running in clockwise direction (Remote Start Signal)

4

3

2

1 Remote direction switch in counter clockwise direction

Remote Control Wiring schematic

4

3

2

1

Start and direction controlled from tool itself

4

3

2

1

Start Rev

40

DS/DL Drive

3.16 Inputs and Relays The Figure below shows how to connect in order to obtain a signal on one of the inputs. The power source can either be built in 24 VDC or an external power source.

4

14

15

16

17

18

+

-

19 20

21 22

2.2k

2.2k

+24VDC

0V

+

-

+

-

+

- DI1

DI2

DI3

+

- DI4

41

DS/DL Drive

The figure below shows how to connect to obtain OK and NOK signals using RE1 & RE2.

RE1

RE2

6

7

8

9

10

11

12

0V +24V

OK

NOK

NO

C

NC

RE11

NO

C

NC

5

4

3

2

1

RE2

NC

C

NC

RE3

NO

C

NC

RE4

42

Programs

4. Programs 4.1 Selection of program Full Programming

With Full Programming the most detailed programming can be made. Here you can choose between the four different tightening strategies Two Stage, Quick Step, Ergo Ramp and Rotate Spindle. See chapter 4.2 Tightening Strategies.

Full Programming enables you to fine tune all parameters in order for the tightening to perfectly suit your specific application. The parameters are explained in chapter 5, Tools Talk DS / DL.

Two Stage With the Two Stage strategy the tool will first perform the first step and then make a complete stop during 50 ms to let the joint relax, thereafter the second step is performed. Since about two thirds of the joint relaxation (on most joints) occurs during the first 30 ms, the two stage strategy provides high quality joints with little joint relaxation. The acceleration in the second step is determined by a ramp called Step 2 Ramp.

43

Programs

Quick Step In Quick Step the tool shifts immediately down to a constant Step 2 Speed at the First Target without stopping between the two stages. This is the fastest strategy and is best suited for joints with constant joint hardness and very soft joints.

Ergo Ramp Ergoramp is a two-stage tightening with constant speed during the second stage. It is set automatically by the programmed value for ergoramp and the hardness of the joint. This strategy has the ergonomical advantage that the user experiences both soft and hard joints as equal. Ergoramp is the correct strategy where there are both hard and soft bolted joints.

Rotate Spindle In the strategy Rotate Spindle the spindle rotates a pre-set number of turns and when finished, the tool gives an OK signal. If the torque exceeds the rotating torque max, the tool stops and gives a NOK signal.

Autoset If you use the Auto Set, the Drive will do the programming automatically. You will find it in the upper right corner of the programming window or in the Pull down menu under DS/DL Drive or on the key pad on the drive. You do not have to do any programming at all, you only need to perform a few test tightenings. During these test tightenings the Drive will do its own programming. Each tightening will reach the Final target entered by the operator, but at different speeds and strategies. The Drive will customise the programming to the specific joint you are running on.

44

Programs

Note! The first test tightenings are performed at a very low speed. The Auto Set is only available when a Drive is connected. When you click Auto Set a dialogue window asking you to enter the Final target is displayed. When you have entered your value click OK. A window asking you to perform the tightenings will appear. Normally 5-10 tightenings are required for the Drive to find a program suitable for the particular joint characteristics.

While performing the test tightenings a green light on the Drive, marked with a graph, is activated. When this signal light is turned off the Auto Set is finished and the Drive is now programmed according to this specific joint. The Programming window in ToolsTalk DS/DL still displays the old settings. To update the Programming window with the new settings from the Drive simply click the Store button.

45

Programs

Quick programming

Quick programming window

The Quick programming mode is meant to help you program the DS/DL Drive in a very simple way. It only requires two pieces of information about your joint, the Final Target and the Joint Angle from Snug. All other parameters are automatically calculated by the system. Quick programming results in a Quick Step tightening. Quick Programming automatically sets the Torque Tuning Factor to its default value, 100.

Angle from snug is the angle from when the head of the bolt reaches the surface and the torque starts to increase.

46

Programs

Final Target and Angle from Snug The Final Target is the specified torque for the joint.

The angle from when the bolt head encounters the work piece to when the final target is reached. On hard joints it is advisable to set it on 10 degrees. For soft joints you can calculate this angle as follows:

1. Enter the Final Target and set the Angle from Snug to 10. Click OK. Change the strategy to Two Stage and press the Store button.

2. Make one tightening. The bolt will then be tightened to the correct torque using a very low first target that is automatically set by the system to manage a hard joint.

3. Use a spanner, wrench or equal to untighten the bolt, and estimate how many degrees it takes from fully tightened to the bolt is loose.

4. Enter the angle value found in step 3 as Joint Angle from Snug.

Note! It is recommended that the Angle from snug is set to 10 degrees or more. As mentioned above, on hard joints it is recommendable to set the Angle from Snug to 10 straight away. By setting the Angle from Snug to 10 the Drive will make a very careful rundown with a low First Target. If you feel that the second stage is too long, just raise the angle until you are satisfied.

However, it is important that there is a second stage otherwise you risk to get an overshoot. The socket has to move a little in the second stage.

The Quick programming mode will get your tool running in no time, but to fully utilise the performance of the Tensor DS/DL System we recommend that you dig intoFull programming in chapter 6. Full programming enables you to fine tune all parameters in order for the tightening to perfectly suit your specific application.

4.2 Tightening strategies When programming, it is important to have a well developed second stage. The socket shall make an angle movement at the second stage, otherwise the torque may become to great. The best way to see that there is a second stage is simply to observe the socket movement.

If the tool exceeds the torque, a red warning light will illuminate. The explanation is a short or no second stage in combination with high speed in the first stage.

Insufficient torque is lower than 98% of the final torque and is probably caused by releasing the trigger on the tool too early. A yellow light on the tool indicates an insufficient torque.

47

Programs

Two stage

Torque

Speed

Soft Start

Step 1 Speed

First Target

Final Target

Time

Step 2 RampStep 2 Speed

Zoom Step Speed

For two stage tightening, the tool has a very high speed during the first stage and lower during the second stage. The tool stops for about 50 ms between stages to reduce settings and then accelerates up to the speed for the second stage.

48

Programs

Quickstep

Torque

Speed

Soft Start

Step 1 Speed

First TargetFinal Target

Time

Step 2 Speed

Zoom Step Speed

Quickstep is a two-stage tightening with high speed during the first stage and low speed during the second stage. The other stage operates at constant speed. In the end, there is a zoom stage, which reduces tool speed and results in a smoother finish.

In Quick Step the tool shifts immediately down to a constant Step 2 Speed at the First Target without stopping between the two stages. This is the fastest strategy and is best suited for joints with constant joint hardness and very soft joints.

49

Programs

Ergoramp Torque

Speed

Soft Start

Step 1 Speed

First Target

Final Target

Time

Ergo Ramp

Zoom Step Speed

Soft Joint

Ergo Ramp on a soft joint Torque

Speed

Soft Start

Step 1 Speed

First Target

Final Target

Time

Ergo Ramp

Zoom Step Speed

Hard Joint

Ergo Ramp on a hard joint

50

Programs

Ergoramp is similar to Two Stage but the time for the second step is kept constant and the speed in the second step is automatically set due to the ergoramp value and the stiffness of the joint.

This has the ergonomic benefit to make all joints feel the same for the operator despite variations in joint hardness and is ideal for applications where soft and hard joints are mixed.

With the Ergo Ramp strategy the tool will first perform the first step and then make a complete stop during 50 ms to let the joint relax, thereafter the second step is performed. While we in the Two Stage strategy fix the acceleration to be the same for all tightenings within one p-set, the Ergo Ramp feature calculates the speed in the second step with respect to a time set by the Ergo Ramp strategy itself.

When the Ergo Ramp is programmed the Drive sets a time during which the second step shall be performed. When the tool is running, the speed in the second step is calculated during the actual tightening, making the time to complete the second step the same regardless of joint hardness. This means that the speed in the second step varies from joint to joint.

This is a very comfortable strategy for the operator and is perfect when the joint characteristics varies. ErgoRamp will always give you the same reaction force, no matter the joint hardness.

51

Programs

Rotate Spindle

Rotate spindle is a function that allows the operator to get an OK signal when the tool has turned a certain number of turns. The OK signal will be indicated with the green LEDs on the tool, the OK lamp on the drive will be lit up and the OK relay will be pulled. If an RE Alarm is connected the OK lamp will be lit up. The function can for example be used for backing off an exact number of turns.

Rotating torque max This is the maximum torque value while rotating the spindle. The max limit is tool max torque and the min limit is 0. Minimum recommended value is 0.1*tool max torque.

Rotating speed The speed with which the tool will rotate. Can be set between 0 and 100%.

Rotate number of turns The number of turns which the tool will rotate before giving an OK signal.

Tightening direction Tm

5he direction in which the tool will be controlled and the number of turns easured.

2

Programs

4.3 Special Functions Rundown Monitoring

Rundown Monitoring is a function to detect bad rundowns. The angle in both first and second step is monitored. See graph below

53

Programs

Cycle Start Cycle start is the torque limit from which the angle is measured. The maximum limit for Cycle Start is First Target.

Search Speed The search speed is the speed with which the tool will run until Cycle Start limit is reached. The min limit is 0%. Max limit is Step 1 Speed. When Cycle Start is reached the tool immediately accelerates to Step 1 Speed.

Step 1 Turns The angle in the first step is measured from cycle start level until 1st target is reached. It is possible to program min and max levels for when the angle is OK. Min = 0 Turns

Max = 200 Turns

The angle is defined in 1/10 of a full turn.

Clamp Angle The angle in 2nd step is measured from the point where 1st target is reached until final target is reached. The angle in between is called Clamp Angle. It is possible to program min and max levels for when the Clamp Angle is OK.

Min = 0 degrees

Max = 10000 degrees

The angle is defined in steps of 10 degrees.

54

Programs

Low angle If the angle is lower than the min value a twinkling red-yellow light is given on the tool together with the message LO on the display. The tool stops immediately when the angle is out of range. The same functionality for both 1st and 2nd step. The message on the display is LO1 if the angle in step 1 is low and LO2 if the Clamp angle is too low.

High Angle If the angle is higher than the max value a twinkling red-yellow light is given on the tool together with the message HI on the display. The tool stops immediately when the tool is out of range. The same functionality for both 1st and 2nd step. The message on the display is HI1 if the angle in step 1 is too high and HI2 if the Clamp angle is too high.

55

Programs

Self Tap

The Self Tap function is used for thread forming screws and other fasteners with a torque pulse in the beginning of the rundown higher than the desired 1st target or final target. See graph below

Following parameters have to be programmed: Cycle Start Self Tap Torque max Search Speed Self Tap Interval

56

Programs

Cycle Start See Rundown Monitoring

It will be the torque level from which the self-tap interval is measured.

Search Speed See Rundown Monitoring

Search speed is the speed until cycle start and through the Self Tap Interval. After the Self Tap Interval the tool will accelerate to Step 1 Speed.

Self Tap Torque Max Self tap torque max is the maximum thread forming torque allowed. If the torque exceeds that level the tool immediately shuts off giving an error code (E116) on the display.

Self Tap Interval The Self Tap Interval is the thread forming angle. During this interval the torque is allowed to go as high as Self Tap Torque Max. After the interval the speed will be Step 1 Speed and the next torque level is 1st target.

57

Programs

High speed rundown

High speed rundown allows the tool to make the rundown at a higher speed than the actual Step 1 speed. The function is specially designed for fasteners with a long rundown angle and the risk for overshooting due to a stiff joint is big. A certain number of turns are programmed under which the tool will rotate with a higher speed. When the number of turns is reached the tool will slow down to step 1 speed which is so low so that the tool will not overshoot when reaching first target. After this point the tool will finish the tightening like a normal two stage, ergo ramp or quick step tightening.

Safety If the tool shall start with the increased speed it is necessary that the previous tightening was OK.

If the tool is restarted before having received an OK signal it will start at the lower step 1 speed. The reason is to prevent an overshoot because of reaching first target too early at the higher speed.

Speed The increased speed during High Speed Rundown.

Number of turns The number of turns with which the tool will rotate. The angle will be measured from start of the tool.

58

ToolsTalk DS/DL

5. ToolsTalk DS/DL ToolsTalk DS/DL, is an Atlas Copco

software for programming the DS and DL drives. It is based on and designed for Windows 95, 98, 2000, and NT, in other words 32 bit Windows. TTDS/DL can be used to configure the entire functionality of the DS/DL drive.

5.1 Installation Begin the installation procedure by checking that your PC or Lap Top has the required capacity according to the following specification. Then, follow the directions under the heading Proceed as follows.

PC-specification - Operating system Windows 95, 98, 2000, XP, NT

- Available memory: minimum 25 MB on the hard drive and 8 MB RAM

- RS 232 COM port for communication with DS/DL Drive

- Super VGA screen.

59

ToolsTalk DS/DL

Proceed as follows 1. Check that you have the CD-disc with the

Tools Talk program.

2. Insert the CD-disc in D:\drive or 3,5 floppy disc in the A:\drive.

3. Select RUN in START-menu.

4. Type in D:\setup.exe or A:\setup.exe and click on OK.

5. Follow the instructions in the installation program.

6. Click on Ready when the installation is finished.

7. Turn off and then re-start your PC.

The installation is now completed.

60

ToolsTalk DS/DL

Shortcut to ToolsTalk You can create a shortcut to ToolsTalk in the following way:

1. Open the Windows Explorer.

2. Go to the directory where you have the ToolsTalk program. In this case: C:\program\atlas copco\toolstalk\.

3. Click on the file TT DS/DL.

4. Go to File and click on CREATE SHORTCUT. 5. Click on the icon with the right mouse button, keep the button pressed

down and move it to the desired position on the Desktop.

6. Then, by double-clicking on the icon, you can access ToolsTalk directly.

Start up When you start the program, TT DS/DL will automatically make contact with the DS/DL Drive. If you have a Drive connected all the programming in the Drive will be read down by TT DS/DL. When this is finished you will access the programming window in Tools Talk DS/DL.

If you wish to make your programming in advance and load it into the DS/DL Drive at a later stage you probably want to run TT DS/DL without having a Drive connected. When you start TT DS/DL without having a Drive connected TT DS/DL will at start up and try to connect to the Drive, but as the Drive is not present TT DS/DL will not find the Drive and displays the following dialogue box.

Connection with DS/DL Drive failure dialogue box

61

ToolsTalk DS/DL

Click Abort and continue with your programming, see Programming without having the DS/DL Drive connected. The first thing you will have to do is to set the max. torque for the tool, chapter 8, and also specify the Drive version to use, D302 / D303 or D312 / D313.

However, if you do have a Drive connected to the PC and still get this message there is a problem in the communication between the PC and the Drive. Please check the following:

That the Drive is powered on

That you have the correct cable and that it is plugged in correctly.

That the COM port on the computer used by ToolsTalk is not configured for something else. Click Options and then Communications and select another COM port to check the configuration. You might also have your COM ports under the control panel on your PC/lap top.

That your PC is OK

When you have checked this click Retry.

62

ToolsTalk DS/DL

5.2 Working in Tools Talk If you are familiar to using Windows, you will soon be comfortable with TT DS/DL. The program layout, menus and the way of working is similar to Windows.

If you are unsure of the way to work with Windows, ask for assistance from a person who can instruct you and get you started with the program. After some practise, you will be able to manage on your own.

Connection to local networks and serial connection of equipment requires knowledge of addresses and experience from making such connections. Contact your system administrator.

When you start the program, you will first see the window shown below.

Menu row Toolbar

63

ToolsTalk DS/DL

Menu row We will now look at the functions in the menu line.

File When you open File, you can open, save and close files, print and close the program.

Edit In the Edit menu, you have the functions Cut, Copy and Paste.

You can also copy and paste parameter sets.

Drive Drive, you connect the DS/DL Drive and read data from or to the Drive.

When Read All Data From Drive or Store All Data To Drive is selected, both programming and configuration windows are read/stored.

64

ToolsTalk DS/DL

Drive Commands If you click DS/DL Drive in the pull down menu you can choose between DS/DL Drive Commands: Do Motor Tuning Connect Read All Data from Drive and Store All Data to Drive

Do Motor Tuning In order for the motor to run smoothly it needs to be correctly motor tuned. This is done in the factory before delivery, but it is advisable to do a Motor tuning on each specific combination of Drive and Tool together. This can of course only be done when a tool is connected. When you click Do Motor Tuning a dialogue box asks you if you really want to do the motor tuning.

If you click Yes another dialogue box telling you to press the tool trigger will appear. It is important that you keep the trigger pressed during the whole procedure. The tool will turn in both directions, accelerate etc. in order to fine tune the position of the rotor. Do not release the trigger until you get a Motor tuning Succeeded message on the screen. If you release the trigger too early you can click abort and you are back where you started.

Open end Tuning If you already have marked the Open End box, you can perform Open End Tuning. The Open End Tuning will re-perform the tuning and calculate a new gear ratio and play in the gears. The reason for performing a Open End Tuning could for example be if the tool does not find the open space in the gear

65

ToolsTalk DS/DL

Connect To connect the PC to the Drive you click Connect. When a Drive is connected there is a check mark before the text Connect. To disconnect the Drive you can click Connect again.

Read All Data from Drive Choosing this alternative will read all data, including all p-sets and the configuration, from the Drive into ToolsTalk DS/DL.

Store All Data to Drive When you click Store All Data to Drive everything that you have entered into ToolsTalk DS/DL, all p-sets and the configuration, will be stored in the memory in the Drive.

66

ToolsTalk DS/DL

Options If you click Options in the pull down menu you can choose between View Toolbar, Set max. Torque/Drive Version and Settings.

View Toolbar View Toolbar is an On/Off function that removes the Toolbar from the screen when Off.

Set Max. Torque/DS Version Set max. Torque/Drive Version is a function that is only active when no tool and/or Drive is connected.

When a tool is connected the Max. Torque for that tool is automatically handled by ToolsTalk DS/DL. If, however, you wish to do the Programming without having the DS/DL Drive connected, then you set the Max. Torque and Drive version for your programming yourself with this function.

Settings In Settings you can choose between Communication, Options and Printout, all of them are described below.

67

ToolsTalk DS/DL

Communication Under Communication you can choose which COM port ToolsTalk DS/DL will use. Be sure that the COM port chosen is not configured for something else since this will disturb the functioning of ToolsTalk DS/DL.

If you have problems during start up, try to choose another COM port.

Note! The choice of COM port can only be done when the Drive is disconnected from the PC.

Options Under Options you can decide whether the communication between the PC/TT DS/DL and the Drive should be logged or not logging. If for some reason a problem would occur, the saved logging could help the Atlas Copco software specialists to find the reason for the problem and chances increase that it can be solved.

Selecting Hints will give you small yellow Pop Up hints that help you when working in ToolsTalk DS/DL. For example explanations of icons.

Printout Under Printout you can write your own printout footer, i.e. your own notations on the bottom of each side of the printout.

You might want to do some notations on the printout specific for your workshop.

The printout footer enables you to create your own standard for these notations.

68

ToolsTalk DS/DL

Window Here, you can see the available functions. The other alternative is to activate the functions by clicking the icons.

The functions of the other commands are similar to them in Windows.

Help In the Help function, it is possible to open help files for instructions.

Info In Info you will find a short information about Tensor DS/DL.

69

ToolsTalk DS/DL

Toolbars in TT DS/DL

Symbol Designation Explanation

Open file If you want to open a file with programming that is saved on the hard disc or on a diskette you click here. For more information about programming from file see Programming the Drive from file in chapter 6.

Remember that when you open a file it will automatically update the Programming Window with the new programming. If you do not click Store the new programming will not be stored in to the drive memory. For more information about Store see chapter 6.

Save file To save programming on hard disc in or on a diskette click here. For more information about saving programming on file see in chapter 6.

Cut If you mark a value and click here, the value is copied into the clipboard and disappears from the screen.

Copy If you mark a value and click here, the value is copied to the clipboard while it remains on the screen.

Paste When you click Paste, whatever is copied to the clipboard at that moment will be copied back in to the document and placed where the marker is currently positioned.

Print The Print icon will print the information in the currently selected window, except for the Main Window and the Rundown Window, and is therefore only lit up when a window is active. To print information from all windows or to change printer, choose File and Print in the pull down menu.

Open Programming window

Clicking here will open the Programming window, for more information see Programming Windows in chapter 3.

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Open Run window Clicking here will open the Run window, for more information see Run Window in chapter 5.4.

Open Torque Tuning window

Clicking here will open the Torque Tuning window, for more information see Torque Tuning Window in chapter 5.5.

Open Configuration window

Clicking here will open the Configuration window, for more information see Configuration Window in chapter 5.6.

Open Diagnostics window

Clicking here will open the Diagnostics window, for more information see Diagnostic Window in chapter 5.7.

Make contact with the Drive

When the PC does not have contact with the Drive the upper icon is visible. Clicking here will establish contact between PC and Drive.

When the PC has contact with the Drive the lower icon is visible. Clicking here will disconnect the PC from the Drive. Remember to Store before disconnecting.

Help If you click here you will get into the ToolsTalk DS/DL Help files that hopefully can help you solve any programming problems you might have run into.

The function is not activated in this program version.

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5.3 Programming Window

The Programming window is the most important window in ToolsTalk DS/DL Here you set all the torque parameters that the DS/DL Drive uses to control the tool. The programming can be done in three different levels: Auto Set, Quick Programming and Full Programming. The Programming window is different in the two Drive versions, D302 / D303 and D312 / D313. In D302 / D303 you do not have the possibility to change and open parameter sets.

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Auto Set only requires the Final Target, the rest of the parameters are calculated and programmed automatically by the Drive while you perform a number of test tightenings. The Auto Set function does not require the PC to be connected, it can be done by using the keypad on the Drive, see Auto Set in chapter 6.4.

Quick programming: The Quick programming window does not require any knowledge about the Tensor DS/DL System. All you need to know is the Target Torque and the approximate hardness of your joint. The Quick programming window is shown when you click Full Programming on in chapter 6.2 and disappears when the programming is done.

Note! The Quick programming in chapter 6.3 results in a Quick Step strategy for the tightening, for more information on strategies see Full programming in chapter 6.2.

Full programming: In the Full programming window the complete range of settings is accessible. This is where the skilled programmer fine tunes his DS/DL Drive programming. The Full programming window is the one that you open by clicking the Programming icon in the tool bar.

Important! The values entered will not be active in the drive until the Store button is clicked. When a new value is typed followed by Enter it is stored into the Drive directly.

The p-set performed by the Drive is always the selected p-set.

From the Programming window you manage your p-sets. Further you can reach the Torque Tuning window by clicking Torque Tuning. This can only be done if the viewed p-set is the same as the selected p-set.

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Programming window, D302 / D303 Programming window, D312 / D313

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2

3

4

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1. Tightening strategy You can select strategy choices as shown beside.

The strategy Rotate Spindle is only available for D312 / D313 drive.

2. Soft Start Time In order to facilitate screw engagement the tool starts by turning at a very low speed during the soft start time.

3. First Target At this torque level the tool will shift from Step 1 Speed to Step 2 Speed. What First Target to use depends on the joint hardness. On a hard joint it must be quite low to prevent overshoot, while on a soft joint it should be close to the Final Target in order to make the rundown time as short as possible. Make sure that the First Target is set low enough to allow a two stage tightening. A one stage tightening indicates a possible overshoot.

4. Final Target At this level the tool stops and the tightening is finished. It is very important that the fastener turns at least 10 degrees in the second step. This is easily determined by looking at the fastener while the second step is being performed. If the fastener does not turn at all after the first step you should first lower the First target and if this does not help you lower the Step 1 speed. It is recommended to always keep the Step 1 Speed as high as possible.

5. Step 1 Speed The speed with which the tool runs during the first step. On extremely hard joints it might not be enough to lower the First Target to prevent overshoot. The next action to be taken in that case is to lower the Step 1 Speed a little.

6. Step 2 Speed The speed in the second step.

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7. Zoom Step Speed The speed at which the tool will shut off when Final Target is reached.

8. Step 2 Ramp In Step 2 Ramp you can select the acceleration of the tool in step 2 between 0 and 100%.

9. Batch Size Batch Size defines the number of joints in a batch. See also Run Window in chapter 5.4.

10. Tightening Direction Here you can choose between clockwise tightening, CW, and counter clockwise tightening, CCW.

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1 High speed rundown You can select High Speed Rundown ON/OFF, see chapter 4.3 High Speed Rundown.

1 2 3 4 5 6 7 8 9 10 11

2 Options You can select options as shown beside.

Rundown Monitoring: The rundown and tightening angles during tightening are measured.

Self Tap: This function makes it possible to tighten bolted joints where the torque during tightening is higher than the final target. For example, this may be the case when tightening self-tapping screws. For more information, see chapter 4.3.

3 Auto Set Auto Set only requires the Final Target, the rest of the parameters are calculated and programmed automatically by the Drive while you perform a number of test tightenings. The Auto Set function does not require the PC to be connected, it can be done by using the keypad on the Drive.

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4 Quick programming The Quick programming window does not require any knowledge about the Tensor DS/DL System. All you need to know is the Target Torque and the approximate hardness of your joint. The Quick programming window is shown when you click Quick Programming button and disappears when the programming is done. If Quick Programming has been used, this will be indicated with a red frame around the Quick Programming button. Note! The Quick Programming results in a Quick Step strategy for the tightening.

5 Selected Parameter Set, D312 / D313 only By clicking here you get a list of all opened psets in the drive. By marking one and releasing the mouse the pset is selected in the drive.

6 New Pset Here you open psets. New psets will be set to default programming.

7 Reset Pset Set all parameters to default values. Default values are depending on the max torque value on the tool used.

8 Delete Pset Here you delete psets. New psets will be set to default programming.

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9 Torque Tuning All Drives and tools are normalised from delivery. This means that you can use any tool with any drive and the torque will be accurate.

However, sometimes variations in joint characteristics result in a need to fine tune the system in order to get exactly the correct torque on that specific application. See also Torque Tuning in chapter 5.5.

10 Read Reads the current configuration from Drive.

11 Store Stores the current configuration to Drive.

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5.4 Run Window

1 2 3 4 5 6

1. Torque The resulting torque for each tightening.

2. Step 1 no. of Turns The number of turns in 1/10 of a full turn, measured in Step 1. The angle is measured from cycle start until end of Step 1. For more information, see Rundown Monitoring, chapter 4.3.

3. Clamp Angle The angle from end of Step 1 until final target is reached. See also Rundown Monitoring, chapter 4.3.

4. Batch Counter The Batch Counter is incremented by 1 for each OK tightening. When the Batch Counter reaches the number in Batch Size the counter is reset to zero and the nxOK signal light on the Drive is activated.

5. Number Of Rundowns The number of rundowns performed since the window was opened or since Counter Reset was activated

6. Counter Reset

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5.5 Torque Tuning Window

1 2 3 4 5 6 7

All DS/DL Drives and tools are normalised from delivery. This means that you can use any tool with any drive and the torque will be accurate. Of course the Drive has to be of the correct size, DS4 Drive for DS4 tools etc. However, sometimes variations in joint characteristics result in a need to fine tune the system in order to get exactly the correct torque on that specific application. This is done in the Torque Tuning window. To determine if you need to do a Torque Tuning or not you can check the torque with an in-line transducer.

How to perform the Torque Tuning Run the tool together with an in-line transducer on the specific application. It is important that it is on the real application since a test joint might behave differently.

1. Reference Torque The value from your reference system, in-line transducer, torque wrench etc.

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2. Update Chart After each rundown input the reference torque (in-line transducer torque, NOT the torque shown on the Drive unit) in the field Reference Torque and press Enter or click Update chart. For each tightening the graph to the left will be updated and the mean value of the reference torques will be displayed. Further a new tuning factor will be calculated and displayed in the lower right part of the screen

3. Reference Torque Counter The number of tightenings to ensure a good tuning factor must be at least 10, preferably 25.

4. Clear Last and To erase the last entered Reference Torque simply click Clear Last.

5. Clear All To restart the torque tuning procedure click Clear All and all entered values will be erased.

6. Tuning Factor The Torque Tuning results in a Torque Tuning Factor, displayed in the bottom right corner of as well the Torque Tuning window as the Programming window. The Torque Tuning Factor is allowed to differ from the default value, 100 in a range from 20 to 220. If the Torque Tuning Factor is outside this range the field containing the new Factor value will be marked red and it is no longer possible to store the Torque Tuning Factor to the Drive.

The Torque Tuning Factor can also be altered manually, without performing any tightenings. This requires good knowledge of how the Tensor DS/DL works on the specific joint in question.

However, if you for example want a slight increase in the mean value of your tightenings in a particular p-set without changing the programming, you can increase the Torque Tuning Factor by a few units.

Note! The Torque Tuning Factor is specific for each combination of Drive and Tool. It is recommended to perform a Torque tuning on each combination individually.

7. Store Torque Tuning When a sufficient number of tightenings has been made you click Store Torque Tuning and the new Torque Tuning Factor will be stored in the Drive

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Torque Tuning window, 25 tightenings made

If you would enter a value that is outside 15% of target you will get an information dialogue box that looks as follows

Information dialogue box, torque outside recommended values

If you click OK the value will be used by TT DS/DL when calculating the new Torque Tuning Factor but if you click Cancel it is discarded.

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Important about Torque Tuning If the program in ToolsTalk DS/DL is not the same as the program stored in the Drive, then a dialogue window with the question Store changes before Torque Tuning? appears. Clicking Yes means the programming in ToolsTalk DS/DL will be stored into the memory in the Drive and you can proceed with your Torque Tuning. This procedure is designed to prevent operator mistakes, since the Torque Tuning function is performed with the values in the drive as a basis, not the values in ToolsTalk DS/DL / DL.

When Store Torque Tuning has been done you can not retrieve the old tuning factor from the Drive. However, the default tuning value from delivery is always 100.

When service has been made to the tool remember to make some rundowns on a joint and run the tool in the air for some 30 seconds before the Torque Tuning is performed. This will make the grease in the gears settle first so the output torque will not change over time.

The Torque Tuning Factor is closely related to the programming used when the Torque Tuning was performed. If you change the programming substantially you should also redo the Torque Tuning in order to get a perfect result.

Note! If you choose Quick Programming the Torque Tuning Factor is always set to its default value, 100.

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5.6 Configuration Window, Tensor DS & DL In the Configuration window you set the configuration for the DS/DL Drive. The Configuration window has three different subgroups: System Administration, I/O Configuration (containing I/O Setup and RE-Alarm Setup) and Tool Service Setup. In System Administration you define the operator interface.

In I/O Configuration I/O you define how to use the different input and output connections on the DS/DL Driv